Systems and methods for a weld training system

ABSTRACT

An example weld training system includes: an orientation device; a mobile device; and a mount configured to attach the mobile device to a welding accessory, wherein the mobile device comprises: one or more sensors including at least a camera; a processor; and a machine readable storage device storing machine readable instructions which, when executed by the processor, cause the processor to: recognize identifiers on the orientation device based on images captured via the camera; determine at least one of position information or orientation information for a welding torch with respect to the orientation device based on the recognized identifiers; and display, via a display of the mobile device, a welding operation based on the at least the position information or the orientation information.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/101,874, filed Aug. 13, 2018, which is a continuation of U.S. patentapplication Ser. No. 14/554,693, filed Nov. 26, 2014, which claimspriority from and the benefit of U.S. Provisional Patent ApplicationSer. No. 61/911,321, entitled “TRAINING SYSTEM USING A PORTABLE SMARTDEVICE,” filed Dec. 3, 2013. The entireties of U.S. patent applicationSer. No. 16/101,874, U.S. patent application Ser. No. 14/554,693, andU.S. Provisional Patent Application Ser. No. 61/911,321 are incorporatedherein by reference.

BACKGROUND

The present disclosure relates generally to welding systems, and moreparticularly, to a mobile device that may be used as a weld trainingtool for training and/or recruiting purposes.

Welding is a process that has increasingly become utilized in variousindustries and applications. Such processes may be automated in certaincontexts, although a large number of applications continue to exist formanual welding operations. In both cases, such welding operations relyon a variety of types of equipment to ensure the supply of weldingconsumables (e.g., wire feed, shielding gas, etc.) is provided to theweld in appropriate amounts at the desired time.

In preparation for performing manual welding operations, weldingoperators may be trained using a weld training system. The weld trainingsystem may be designed to train welding operators with the propertechniques for performing various welding operations. Various trainingmethods and systems may be utilized within the weld training systems.However, these training methods and systems are generally large andunwieldy, and may be too expensive to produce and utilize in highervolumes. Accordingly, it may be beneficial to provide for low cost weldtraining methods and systems that may be readily produced and utilizedin higher volumes.

BRIEF DESCRIPTION

In an embodiment, weld training system is provided. The weld trainingsystem includes a welding torch configured to perform a weldingprocedure and a mobile device coupled to the welding torch. The mobiledevice is configured to detect, via one or more sensors, dynamicposition or orientation information of the welding torch during thewelding procedure to determine one or more operating parameters of thewelding procedure. The mobile device is also configured to display awelding environment based at least in part on the one or more operatingparameters.

In another embodiment, a weld training system is provided. The weldtraining system includes a welding torch configured to perform asimulated welding procedure on a simulated weld joint on an orientationdevice. The welding training system also includes a mobile devicecoupled to the welding torch. The mobile device includes a cameraconfigured to detect one or more of a plurality of identifiers disposedon the orientation device. The mobile device also includes a processorconfigured to determine dynamic position or orientation information ofthe welding torch based at least in part on the one or more of theplurality of identifiers detected by the camera.

In another embodiment, a non-transitory computer-readable medium storingcomputer instructions is provided. The computer instructions areconfigured to perform, via a welding torch of a weld training system, avirtual welding procedure on a simulated weld joint with respect to anorientation device. The orientation device is a simulated work surface.The computer instructions are configured to receive, via one or moresensors disposed with a mobile device coupled to welding torch, dynamicposition or orientation information of the welding torch. The computerinstructions are configured to determine, via processing circuitrydisposed within the mobile device, updated position or orientationinformation of the welding torch based at least in part on the receivedposition or orientation information. The updated position or orientationinformation is utilized to determine one or more operating parameters ofthe virtual welding procedure.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a weld training systemutilizing a mobile device coupled to a welding torch, in accordance withaspects of the present disclosure;

FIG. 2 is an embodiment of the mobile device coupled to the weldingtorch of FIG. 1 , in accordance with aspects of the present disclosure;

FIG. 3 is an embodiment of the mobile device coupled to the weldingtorch of FIG. 1 , where the mobile device is utilized with anorientation device, in accordance with aspects of the presentdisclosure; and

FIG. 4 is an embodiment of a screen illustrating data corresponding to asimulated, augmented, or virtual reality welding environment, inaccordance with aspects of the present disclosure.

DETAILED DESCRIPTION

Embodiments of the systems and methods described herein relate to a weldtraining system that utilizes a mobile device. In certain embodiments,the mobile device may be coupled to a welding torch of the weld trainingsystem, and an operator may engage the welding torch and the mobiledevice to perform a simulated welding experience for training orrecruiting purposes. In particular, the mobile device may be configuredto provide sensor feedback information related to the simulated weldingexperience to the weld training system and/or the operator. For example,one or more sensors disposed within the mobile device may be configuredto detect position or orientation information of the welding torchduring the simulated welding experience. Further, based on the positionor orientation information detected, the mobile device may be configuredto display a visual representation of a virtual welding environment on adisplay of the mobile device or on an external device. In addition, themobile device may be configured to determine one or more operatingparameters of the simulated weld during the simulated welding experienceand, in certain embodiments, may display the one or more operatingparameters on the display of the mobile device or the external device.

In certain embodiments, the welding torch and the mobile device may beconfigured to perform the simulated welding experience using anorientation device. For example, the orientation device may be aprefabricated two-dimensional or three-dimensional material having aseries of identifiers (e.g., various patterns of dots, textures, raisedsurfaces, barcodes, QR codes, etc.) that orient the welding torch andguide the operator performing the simulated weld. In some situations,the orientation device may be configured for a particular type or aparticular series of simulated welds. In certain embodiments, the mobiledevice may utilize one or more cameras or optical sensors to detect theidentifiers on the orientation device to orient the welding torch whilethe particular type or series of simulated welds is performed relativeto the orientation device.

In certain embodiments, the mobile device of the weld training systemmay be coupled to a welding torch performing an actual welding procedure(e.g., live welding arc, live-arc mode). In these situations, the weldtraining system may enable an augmented welding experience configured toenable training using augmented reality simulation. For example, themobile device may be configured to provide a live video of the weldingoperator performing an augmented reality weld, live video of a weldingarc, live video of a weld puddle, and/or simulated video of a weldingoperation. Furthermore, in certain embodiments, the mobile device mayprovide real-time feedback information on relevant process parameters ofthe augmented welding process that further guides the operator duringthe augmented welding experience.

In this manner, the operator may engage in a real-time simulated weldingexperience or a real-time augmented welding experience for training orrecruiting purposes via a low cost weld training system. Specifically,the low cost weld training system described herein may be utilized andreproduced in higher volumes. It should be noted that the mobile devicemay also be configured to provide post-weld feedback providing a summaryof the relevant process parameters of the simulated or augmented weldingexperience, including the operator's actions.

As used herein, the weld training system may include any suitablewelding related system, including, but not limited to, a weldingtraining system, a live welding system, a simulated welding system, avirtual reality welding system, a welding training application (e.g.,utilized on a mobile device), a welding training system utilized on agaming platform, and so forth. In certain embodiments, the weld trainingsystem may be configured to perform a virtual welding operation, ashielded metal arc welding (SMAW) process, a gas-metal arc welding(GMAW) process, a tungsten inert gas (TIG) welding process, a plasmacutting process, or any other type of welding process.

FIG. 1 is a block diagram of an embodiment of a weld training system 10,in accordance with aspects of the present disclosure. As noted above,embodiments of the weld training system 10 include any suitable weldingrelated system, including a welding application executed using the weldtraining system 10 that enables a simulated or an augmented weldingexperience. In certain embodiments, the weld training system 10 includesa mobile device 12, which may be any personal mobile device and/orportable mobile device. For example, the mobile device 12 may be acellular phone (e.g., smart phone, iPhone®, Android® phone, Windows®phone, Blackberry®), a tablet computer, a laptop computer, a personaldata assistant (PDA), and so forth. The mobile device 12 may havevarious sensors (e.g., accelerometers, gyroscopes, cameras,magnetometers, GPS) disposed within a sensor system 14 as describedbelow, a memory to store data and instructions, and a processorconfigured to receive feedback from the sensors and to executeinstructions for the mobile device 12. In some embodiments, the mobiledevice 12 includes a display screen configured to display information(e.g., graphical simulated welding experience, augmented weldingexperience, weld parameters) to the operator.

In particular, the illustrated embodiment depicts the mobile device 12communicatively coupled to a welding torch 24. The mobile device 12 ofthe weld training system 10 includes one or more processors 16 (or anycomputing component), memory device(s) 18, storage device(s) 20, and adisplay 22. The processor(s) 16 may be used to execute software, such aswelding software, a welding application, image processing software,sensing device software, and so forth. Moreover, the processor(s) 16 mayinclude one or more microprocessors, such as one or more“general-purpose” microprocessors, one or more special-purposemicroprocessors and/or application specific integrated circuits (ASICS),or some combination thereof. For example, the processor(s) 16 mayinclude one or more reduced instruction set (RISC) processors.

The memory 18 may include a volatile memory, such as random accessmemory (RAM), and/or a nonvolatile memory, such as read-only memory(ROM). The memory device(s) 18 may store a variety of information andmay be used for various purposes. For example, the memory device(s) 18may store processor-executable instructions (e.g., firmware or software)for the processor(s) 16 to execute, such as instructions (e.g.,application) for enabling a simulated or augmented welding experiencevia the mobile device 12 and/or instructions to communicate feedbackinformation from/to the mobile device 12. In addition, a variety ofcontrol regimes for various welding processes, along with associatedsettings and parameters may be stored in the storage device(s) 20 and/ormemory device(s) 18, along with code configured to provide a specificoutput (e.g., initiate wire feed, enable gas flow, capture weldingcurrent data, detect short circuit parameters, determine amount ofspatter, etc.) during the simulated or augmented welding operation.

The storage device(s) 20 (e.g., nonvolatile storage) may include ROM,flash memory, a hard drive, or any other suitable optical, magnetic, orsolid-state storage medium, or a combination thereof. The storagedevice(s) 20 may store data (e.g., data corresponding to a simulated oran augmented welding operation, video and/or parameter datacorresponding to a simulated or augmented welding operation, etc.),instructions (e.g., software or firmware for the welding system,software for the welding application, software to enable communicationsand/or control with the mobile device 12, etc.), and any other suitabledata. As will be appreciated, data that corresponds to the simulated oraugmented welding operation may include a video recording of the weldingoperation, a simulated or augmented video, an orientation and/or aposition of system 10 components, a work angle of the welding torch 24with respect to a simulated or real workpiece, a travel angle of thewelding torch 24 with respect to a simulated or real workpiece, a travelspeed of the welding torch 24 with respect to a simulated or realworkpiece, a distance between components of the system 10, a voltage, acurrent, a traversed path, a discontinuity analysis, welding devicesettings, and so forth.

As discussed above, the mobile device 12 comprises the display 22configured for displaying data and/or screens associated with thesimulated or augmented welding process (e.g., to display data generatedby welding software), among other things. The display 22 may provide agraphical user interface to a welding operator (e.g., weldinginstructor, welding student, etc.). For example, the graphical userinterface displayed by the display 22 may provide various screens toenable the operator (e.g., welding student, welding gamer, weldingtrainee, etc.) to perform the simulated or augmented welding task, viewreal-time feedback of the simulated or augmented welding parameters,view a post-welding summary of the simulated or augmented welding task,view averages and/or results from prior simulated or augmented weldingtasks, compare and view final welding scores of one or more weldingoperators, and so forth. In certain embodiments, the display 22 may be atouch screen display configured to receive touch inputs, and to providedata corresponding to the touch inputs to the mobile device 12. In someembodiments, the display 22 is configured to display informationcorresponding to sensing device software, and provide a virtual and/orsimulated image of the weld being performed, as further described below.

As noted above, the mobile device 12 may include a welding applicationdisposed on the memory device(s) 18 and executed by the processor(s) 16.Further, an operator may engage the welding application via the display22. For example, the welding application may allow an operator to selectfrom various types or sequences of weld geometries, such as a T, fillet,butt, or other geometry, as well as the orientation of the weld (e.g.,flat, horizontal, vertical, overhead). Based on the selected parametersof the simulated weld, the welding application may commence. In certainembodiments, after the operator engages a trigger on the welding torch24 or the welding process is selected on the display 22, and as thewelding torch 24 is moved, the sensor system 14 of the mobile device 12may gather position and/or orientation information of the welding torch24 as sensor feedback information. Based on the sensor feedbackinformation, the display may graphically illustrate the welding torch 24coming into position with respect to a simulated joint within asimulated welding environment.

In certain embodiments, the display 22 may display a menu where theoperator 16 is able to specify settings such as the type of weldingapplication, the mode of welding (e.g., simulated mode, live-arc mode,or augmented mode, among other modes), the weld joint geometry, theorientation, the material thickness, the wire feed speed, and thevoltage. Another embodiment may permit the operator to pick the weldjoint, orientation and material thickness, and the welding applicationof the mobile device 12 may suggest the wire feed speed and the voltage.The operator may then be able to adjust settings off of a starting pointor accept these parameters. Based on travel speed, angles andorientation detected by the sensor system 14, the mobile device 12 maybe configured to simulate the weld. As skill improves, the simulatedweld by the operator will be at the desired location in the joint andthe right width due to travel speed, angle, and orientation.

In certain embodiments, the mobile device 12 may utilize sensor feedbackfrom the sensor system 14 to determine parameters like travel speed,wire location with respect to the joint, torch angles and contact tip ortorch to joint/work distance. The processor 16 of the mobile device 12may execute instructions (e.g., software) to utilize sensor feedback tosimulate and display the simulated weld. The software may be availablefor use with the mobile device 12 through various sources, including,but not limited to, a tangible non-transitory storage media (e.g., flashdrive, optical disc, magnetic disc), a network, a website (e.g., amanufacturer website, www.Millerwelds.com), and so forth. In someembodiments, scores and results from simulated welds performed by one ormore operators may also be stored (e.g., in the memory 18) or shared.

In particular, the sensor system 14 of the mobile device 12 may includevarious sensors that sense the movement, position, and/or orientation ofthe mobile device 12 (and, by extension, the welding torch 24 to whichthe mobile device 12 is coupled) relative to a reference point or areference object. For example, the mobile device 12 may have one or more3D gyroscopes for angle information, one or more 3D accelerometers, oneor more proximity sensors, one or more magnetometers, one or more GPSreceivers, one or more Bluetooth sensors, other wireless field sensors,or any combination thereof. The mobile device 12 may utilize one or moreof these sensors to sense a change in speed of the mobile device 12 in adirection and/or an orientation. Feedback (e.g., signals) from the oneor more sensors may be stored in the memory 18 of the mobile device 12for subsequent retrieval and/or transmission to another mobile device, acomputer system, or a network, or any combination thereof. The processor16 of the mobile device 12 utilizes feedback from the one or moresensors in real-time to simulate and display the simulated weldingapplication on the display 22. In some embodiments, the mobile device 12may utilize one or more of these sensors exclusively. In certainembodiments, the sensor system 14 of the mobile device includes one ormore cameras or optical sensors. In certain embodiments, these camerasor optical sensors may be utilized to identify components within theenvironment that guide the simulated or augmented welding application,as further described with respect to FIG. 3 .

In certain embodiments, one or more 3D accelerometers of the sensorsystem 14 of the mobile device 12 may generate signals based at least inpart on acceleration of the mobile device 12 (and thereby theacceleration of the welding torch 24 coupled to the mobile device 12).The signals generated by the 3D accelerometers may be in units of G(e.g., approximately 9.81 m/s²). The total acceleration of the mobiledevice 12 may be approximately equal to the gravitational acceleration(e.g., 1 G) plus the acceleration the user imparts to the mobile device12. The mobile device 12 may separate the gravitational accelerationfrom user imparted acceleration utilizing signals from the one or more3D gyroscopes that are from approximately the same time as the signalsfrom the one or more 3D accelerometers.

Further, in certain embodiments, the sensor system 14 includes one ormore 3D gyroscopes that may be utilized by the mobile device 12 todetermine rotation of the mobile device 12 relative to one or morereference planes. In some embodiments, the one or more 3D gyroscopes maybe utilized with the signals from the one or more 3D accelerometers togenerate gyroscope enhanced motion data including, but not limited to,Euler angles of the mobile device 12 (e.g., pitch, roll, and yaw),attitude quaternion, rotation matrix, the gravitational component of 3Dacceleration, a user acceleration component of 3D acceleration, orrotation rate, or any combination thereof. In some embodiments, theEuler angles of the mobile device 12 determined by the one or more 3Dgyroscopes may be in units of radians or degrees.

Further, in certain embodiments, the sensor system 14 may include one ormore global positioning system (GPS) receivers configured to reportlocation data of the mobile device 12. Location data includes, but isnot limited to, latitude and longitude, magnetic heading relative tomagnetic north, true heading relative to true north, course and speed ofmovement, or altitude, or any combination thereof. As may beappreciated, latitude and longitude may be geographical coordinatesusing the World Geodetic System (WGS) 84 reference frame. Course datamay represent the direction in which the mobile device 12 and/or thewelding torch 14 are traveling in units of degrees. Course values aremeasured in degrees starting at due north and continuing clockwisearound the compass. For example, north is 0 degrees, east is 90 degrees,south is 180 degrees, and west is 270 degrees. Speed data may representthe instantaneous speed of the mobile device 12 and/or the welding torch14, such as in meters per second. This value represents theinstantaneous speed of the mobile device 12 and/or the welding torch 14in the direction of its current heading. The one or more magnetometersmay provide compass direction for the mobile device 12 and/or thewelding torch 14, such as in units of microteslas.

In certain embodiments, the display 22 may depict the simulated weldingenvironment based on the sensor feedback received from the sensor system14. For example, the display 22 may darken to display sparks, the arc,and a glowing weld deposit as a simulation of the weld as feedback oftechnique. A start switch or a trigger on the welding torch 24 or otherdevice such as foot pedal or finger control may be in communication withthe mobile device 12. Additionally, or in the alternative, the simulatedwelding application may be started by touching a start icon on thedisplay 22. Accordingly, after the operator commences the simulatedweld, the display 22 may darken to depict the simulated weldingexperience and environment, and the operator may move the display 22 ofthe mobile device 12 via the welding torch 24 and watch the simulatedformation of the weld for the length of the simulated weldingapplication.

In certain embodiments, instead of a simulated welding environmentwherein the entirety of the simulated weld is generated by the simulatedwelding application, an augmented welding environment wherein live videoof a live arc is augmented with other video and/or information may bedisplayed via the display 22 of the mobile device 12. In suchembodiments, the display 22 may depict the augmented welding environmentbased on the sensor feedback received from the sensor system 14. Forexample, if an operator selects an augmented welding mode from thedisplay 22, the mobile device 12 may be configured for an augmentedreality simulation. As part of this augmented reality simulation, themobile device 12 may receive and display a live video of a weldingoperator performing a real weld with a live arc. Further, based on thesensor feedback received from the sensor system 14, the mobile device 12may integrate a virtual welding environment into the live video of thereal welding application. In this manner, the display 22 may generallybe transparent to enable the welding operator to view actual objectswithin the real welding environment; however, a virtual weldingenvironment may be portrayed on portions of the display 22 to alsoenable the welding operator to view virtual objects superimposed on theactual (i.e., real world) objects captured in the live video. Thevirtual objects may be any number of figures, symbols, text, or imagesthat may guide the welding operator during the actual welding process.

In certain embodiments, components of the weld training system 10 may beused by the operator (e.g., welding student, trainee, gamer, recruiter,trainer, etc.) to perform simulated or augmented welding operations thatprovide the user with a simulated or augmented welding like experience.For example, the weld training system 10 may include the welding torch24 (either as a live-arc torch or dummy torch), a welding power supply24 (that supplies the welding power during live-arc welding), a weldingwire feeder 28 (that supplies welding wire during live-arc welding incertain embodiments), a gas supply 30 (that supplied shielding gasduring live-arc welding in certain embodiments), or any combinationthereof. It should be noted that in some embodiments, the weld trainingsystem 10 may include a gateway 32 to facilitate communication betweenvarious components of the weld training system 10. For example, themobile device 12 may be in wireless communication with the gateway 32 ofthe weld training system 10, and the gateway 32 may receive andcommunicate information (e.g., sensor feedback information related tothe simulated or augmented welding operation, the simulated or augmentedwelding parameters, the post-welding summary of the simulated oraugmented welding task, etc.) to external components of the weldingtraining system 10, such as a display 34 on a welding helmet 36 or anexternal display 38. In some embodiments, the welding training system 10may be coupled via a wired or wireless (e.g., Bluetooth, Wi-Fi, etc.)connection to the welding helmet 36 and/or the external display 38, andmay project feedback into the welding helmet 36. In certain embodiments,the external display 38 may be an augmented reality display, which mayinclude optical projection systems, monitors, hand held devices,head-mounted displays, eyeglasses (e.g., glasses that are configured toaugment a portion of a person's field of view), etc. Angles, coaching,voice, and other information may be useful for feedback when running thesystem with the welding helmet 36 on to more closely simulate weldingwithout the helmet darkening.

Further, in certain embodiments, one or more weld training systems 10may be coupled to a monitoring/analysis system 40. Themonitoring/analysis system 40 may gather information from the one ormore weld training systems 10, and the monitoring/analysis system 40 maybe configured to work off-line or on a network 42 (e.g., Wi-Fi network).The network 42 may communicatively couple the monitoring/analysis system40 to the cloud storage/services 44. The cloud storage/services 44 maycontain information that provide feedback or aid to an instructor oroperator performing a welding process. The weld training system 10 alsomay provide haptic vibration and/or audible feedback to the operatorutilizing a database of information for proper technique, travel speed,and distance, among other training variables. The haptic vibrationand/or audible feedback may be provided based at least in part on ahistory of one or more simulated or augmented welds performed by theoperator. The cloud storage/services 44 may be coupled to a remotecomputer 46 that provides or retrieves information from or to the cloud44.

It should be noted that while aspects of the present embodiments aregenerally described in the context of weld training systems, features ofthe present embodiments may be utilized in other types of weldingsystems, such as those described above.

FIG. 2 is an embodiment of the mobile device 12 coupled to a neck 50 ofthe welding torch 24 of FIG. 1 , in accordance with aspects of thepresent disclosure. The mobile device 12 may be fixedly or removablymounted on the welding torch 24, such as on the neck 50 of the weldingtorch 24, via one or more mounting devices 52. It will be appreciatedthat while illustrated as being coupled to the neck 50 of the weldingtorch 24, in other embodiments, the one or more mounting devices 52 maybe configured to be coupled to other places (e.g., a handle) of thewelding torch 24. In the illustrated embodiment, the operator may moveeither the welding torch 24 or the mobile device 12 in order to engageboth the welding torch 24 and the mobile device 12 for the simulated oraugmented welding process. In particular, the display 22 of the mobiledevice 12 may be positioned on the neck 50 such that it generally guidesthe operator's eyes to look at the welding torch 24 in a desired mannerwhile welding. In certain embodiments, the one or more mounting devices52 may be moveable with respect to the welding torch 24 in order toallow the operator to slightly move, rotate, tilt, or adjust theposition of the mobile device 12 for comfort or ease of operation. Inaddition, in certain embodiments, the one or more mounting devices 50may be configured to be removably coupled to the welding torch 24 attheir appropriate positions with respect to the welding torch 24 suchthat, for example, the one or more mounting devices 50 may be removedwhen the welding torch 24 is not being used for weld training.

As illustrated in FIG. 2 , in certain embodiments, the mounting device52 may include, or be directly coupled to, a shield 54 that isconfigured to hold the mobile device 22 in place with respect to thewelding torch 24 while also protecting the mobile device 12 from weldingmaterials (e.g., spatter) during an actual welding process. In certainembodiments, the shield 54 may be transparent, such that the mobiledevice 12 (and/or the operator) is not restricted in its field of viewduring operation. For example, the mobile device 12 may be able togather information or data (e.g., via a camera that is disposedproximate the shield 54 when the mobile device 122 is held in place bythe shield 54) through the transparent shield 54 during the simulated oraugmented welding process. Further, the welding torch 24 may include atrigger 53. As described above, the start of the simulated or augmentedweld may be initiated via the touch screen display 22 on the mobiledevice 12, or by depression of the trigger 53 of the welding torch 24,or a combination thereof. In some embodiments, additional triggers orswitches may be disposed on the welding torch 24 or on a foot pedal. Thetriggers and/or switches may communicate via wired or wireless (e.g.,Wi-Fi, Bluetooth) connections to initiate start. For example, theoperator may engage the trigger 53 on the welding torch 24 to commence asimulated or augmented welding process. In certain embodiments, themobile device 12 may sense the actuation or release of the trigger 53through a wired connection through the mounting device 52.

In certain embodiments, the mobile device 12 includes a camera 56 (orother optical sensor) that may be a component of the sensor system 14.In certain embodiments, the camera 56 may be utilized to provide a livevideo of the actual live arc during an augmented welding process. Forexample, as noted above, in certain embodiments, the shield 54 may betransparent, and the camera 56 of the mobile device 12 may be configuredto gather information or data through the transparent shield 54.Alternatively, or in addition to, in certain embodiments, the camera 56may be configured to gather information or data through the one or moreapertures disposed on the shield 54. In certain embodiments, the camera56 may be utilized to detect one or more orientation devices 58 during asimulated welding process, as further described with respect to FIG. 3 .Although the camera 56 illustrated in FIG. 2 appears to be on a side ofthe mobile device 12 opposite from an operational end of the weldingtorch 24 when held in place by the mounting device 52, it will beappreciated that the camera 56 of the mobile device 12 may be functionalon both sides of the mobile device 12 such that the camera 56 is capableof collecting video and image data from the operational area around aworkpiece (or an orientation device 58) during a live arc weldingoperation or a simulated or virtual welding operation.

FIG. 3 is an embodiment of the mobile device 12 coupled to the weldingtorch 24 of FIG. 1 , where the mobile device 12 is utilized with anorientation device 58, in accordance with aspects of the presentdisclosure. The orientation device 58 may be a prefabricatedtwo-dimensional or three-dimensional material having a series ofidentifiers 60 (e.g., various patterns of dots, lines, curves, grids,recesses, protrusions, geometric shapes, textures, raised surfaces,barcodes, QR codes, etc.). In certain embodiments, the orientationdevice 58 may be a separate token, a piece of paper, a sheet of plastic,a solid surface, a tag, or the like. The orientation device 58 may beutilized for a simulated welding process, and may be configured toorient the welding torch 24 and guide the operator performing thesimulated weld. For example, the orientation device 58 may be asimulated work surface on which the operator may perform a simulatedweld joint for a virtual or simulated welding application.

In some embodiments, the sensor system 14 of the mobile device 12 mayutilize the camera 56 to detect the identifiers 60 on the orientationdevice 58. For example, the camera 56 may detect a series of patterns ofidentifiers 60 that aid the mobile device 12 in determining where themobile device 12 is positioned relative to a starting point 62 on theorientation device 58, a travel speed of the mobile device 12 (and, byextension, the welding torch 24) relative to the orientation device 58,additional angle information of the mobile device 12 (and, by extension,the welding torch 24) relative to the orientation device 58, anddistance of the mobile device 12 (and, by extension, the welding torch24) to the orientation device 58 for the weld simulation. In someembodiments, the camera 56 may work exclusively without other sensors ofthe sensor system 14 to provide feedback to the mobile device 12. Inother embodiments, the mobile device 12 may utilize the camera 56 andone or more of sensors including, but not limited to one or more 3Daccelerometers, one or more proximity sensors, one or moremagnetometers, one or more GPS receivers, one or more Bluetooth sensors,other wireless field sensors, or any combination thereof. For example,the camera 56 may determine a position and/or orientation of the mobiledevice 12 (and, by extension, the welding torch 24) relative to theorientation device 58, and the other sensors may be used to confirmand/or slightly adjust the determined position and/or orientation. Insome embodiments, the mobile device 12 may sense (e.g., via amagnetometer) small magnets 64 disposed on the orientation device 58 todetermine speed, direction, orientation, and other feedback parametersfor the simulated welding process.

In particular, the camera 56 may detect the patterns of the identifiers60 on the orientation device 58. The identifiers 60 may be unique (e.g.,color, geometry, etc.) and disposed in various locations on theorientation device 58 to enable accurate position and/or orientationinformation for the system 10 (e.g., mobile device 12, welding torch 24,and so forth) relative to the orientation device 58. This unique patternenables the mobile device 12 to determine parameters of the simulatedweld, such as a travel distance, a weld width, a depth, one or moreangles, or any combination thereof. The camera 56 may detect theidentifiers 60, and may provide this information to the processor 16 ofthe mobile device 12. The processor 16 may be configured to extractinformation from the identifiers 60 that orient the welding torch 24with respect to the simulated weld simulated on the orientation device58. In turn, the orientation device 58 may guide the operator throughthe simulated weld. In certain embodiments, the operator may dynamicallyadjust one or more operating parameters of the simulated welding processbased on the detected identifiers (i.e., based on the position ororientation of the welding torch 24 with respect to the simulated weld).

In some embodiments, the one or more sensors in the mobile device 12 areused to help ensure accuracy of the measurements determined via thecamera 56. In other embodiments the camera 56 may be used without theidentifiers 60 and/or the orientation device 58. That is, the camera 56may determine the relative movement and/or the relative orientation ofthe mobile device 12 via utilizing one or more objects in the field ofview of the camera 56 as orientation devices. In such situations, theorientation device 58 may not be needed.

In some embodiments, the mobile device 12 may be mounted to a weldingtorch 24 during an actual welding application to provide angle,position, travel speed, and other sensor information, which may beattributed to the welding torch 24. In other words, when mounted to thewelding torch 24, the mobile device 12 may serve similar functionalityas a retrofit kit for adding the camera 56, sensors, display 22,processor 16, memory 18, and storage 20 of the mobile device 12 to thewelding torch 24, thereby enabling the welding torch 24 to function as amobile weld training system 10. Further, in such situations, the mobiledevice 12 and the welding torch 24 may also be configured for anaugmented welding application. In certain augmented weldingapplications, the mobile device 12 may be placed in various areas on theoperators hand and/or welding torch 24 to provide feedback withoutblocking the actual welding process. The camera 56 may also use variousfiltering means to help track the weld and even display a live feed ofthe actual weld occurring.

In certain embodiments, the portable weld training system 10 canincorporate a competitive, gaming aspect to the simulated weldingexperience provided by the mobile device 12, and can provide a weldingscore to the user based on the received feedback. Further, the mobiledevice 12 may access the storage within the network 42 or cloud 44 tostore and/or retrieve information for each welding operator, such as,for example, user identification information, historical weldinformation, and/or historical welding scores.

FIG. 4 is an embodiment of a screen 70 illustrating data correspondingto a simulated, augmented, or virtual reality welding environment, suchas those generated by the weld training system 10, in accordance withaspects of the present disclosure. The screen 70 may be produced by theweld training software disposed on the mobile device 12, and may bedisplayed on the display 22, the external display 38, and/or the helmet36. The screen 70 illustrates parameters that may be graphicallydisplayed to a welding operator before, during, and/or after performinga simulated, augmented, or virtual reality welding operation. Forexample, the parameters may include a work angle 72, a travel angle 74,a contact tip to work piece distance 76 (e.g., CTWD 76), a welding torchtravel speed 78, a proximity of the welding torch 24 in relation to awork piece 80, a welding voltage 82, a welding current 84, a weldingtorch orientation, a welding torch position, an aim of the welding torch24, a video replay of the simulation, augmented, or virtual realitywelding environment 86, and so forth.

As illustrated, graphically illustrated parameters may include anindication 88 of a current value of a parameter (e.g., while performinga weld training assignment). Furthermore, a graph 90 may show a historyof the value of the parameter, and a score 92 may show an overallpercentage that corresponds to how much time during the weld trainingassignment that the welding operator was within a range of acceptablevalues. As noted above, a video replay 86 of a weld training assignmentmay be provided on the screen 70. The video replay 86 may show livevideo of a welding operator performing the simulated or actual weld witheither a simulated, augmented, or virtual reality environmentsuperimposed thereon.

In some embodiments, a time 94 during a weld may be selected by awelding operator. By selecting the time 94, the welding operator mayview the video replay 86 in conjunction with the welding parameters asthey were at the selected time 94 in order to establish a correlationbetween the welding parameters and the video replay 86. The weldtraining software may be configured to recreate welding data based atleast partly on welding parameter data, to synchronize the video replay86 with the recreated welding data, and to provide the synchronizedvideo replay 86 and recreated welding data to the display 22, theexternal display 38, and/or the helmet 36. Further, in some embodiments,a summary of the post-welding data and/or score may be displayed on asummary page 96 for each welding operator 98. It should be noted that insome situations, the screen 70 may display a comparison of total scoresfor each welding individual 98. Indeed, the weld training system mayinclude or utilize any number of weld training features (e.g., a totalwelding score) or techniques (e.g., comparing weld training information)previously disclosed in U.S. Patent Application Publication No.2014/0272837, entitled “MULTI-MODE SOFTWARE AND METHOD FOR A WELDINGTRAINING SYSTEM,” filed Mar. 15, 2013, which is hereby incorporated byreference in its entirety for all purposes.

While only certain features of the present embodiments have beenillustrated and described herein, many modifications and changes willoccur to those skilled in the art. It is, therefore, to be understoodthat the appended claims are intended to cover all such modificationsand changes as fall within the true spirit of the present disclosure.

The invention claimed is:
 1. A weld training system, comprising: anorientation device; a mobile device; and a mount configured to attachthe mobile device to a welding accessory, wherein the mobile devicecomprises: one or more sensors including at least a camera; a processor;and a machine readable storage device storing machine readableinstructions which, when executed by the processor, cause the processorto: recognize identifiers on the orientation device based on imagescaptured via the camera; determine at least one of position informationor orientation information for a welding torch with respect to theorientation device based on the recognized identifiers; and display, viaa display of the mobile device, a welding operation based on the atleast the position information or the orientation information.
 2. Theweld training system of claim 1, wherein the mount is configured toattach the mobile device to the welding torch.
 3. The weld trainingsystem of claim 1, wherein the instructions cause the processor todisplay the welding operation within an augmented reality environmentbased on the identifiers.
 4. The weld training system of claim 3,wherein the welding torch is configured to perform a simulated weldingoperation on a simulated weld joint on a simulated work surface, andwherein the instructions cause the processor to display the simulatedweld joint and the simulated work surface based on the recognizedidentifiers.
 5. The weld training system of claim 3, wherein the displayof the augmented reality environment comprises a live video of actualobjects used in the welding operation with one or more virtual objectssuperimposed on the actual objects.
 6. The weld training system of claim1, wherein the instructions cause the processor to identify anindication of actuation or release of a trigger of the welding torch,and perform a welding simulation in response to detecting the indicationof actuation of the trigger.
 7. The weld training system of claim 1,wherein the one or more sensors further include at least one of anaccelerometer, a gyroscope, a proximity sensor, a magnetometer, a GPSreceiver, or an electromagnetic field sensor, and the instructions causethe processor to determine the at least one of the position informationor the orientation information based on a combination of an imagecaptured by the camera and the at least one of the accelerometer, thegyroscope, the proximity sensor, the magnetometer, the GPS receiver, orthe electromagnetic field sensor.
 8. The weld training system of claim1, wherein the identifiers comprise at least one of patterns, dots,lines, curves, grids, recesses, protrusions, geometric shapes, textures,raised surfaces, barcodes, or QR codes.
 9. The weld training system ofclaim 1, wherein the instructions cause the processor to implement agaming application based on the at least one of the position informationor the orientation information and the welding operation.
 10. The weldtraining system of claim 1, wherein the mobile device comprises astorage device, and the instructions cause the processor to store atleast one of user identification information, historical weldinformation, or historical welding scores.
 11. The weld training systemof claim 1, wherein the instructions cause the processor to transmit theat least one of the position information or the orientation informationto an external device.
 12. The weld training system of claim 11, whereinthe external device is a device selected from the group consisting of:an external display, a remote computing system, or cloud storage orprocessing.
 13. The weld training system of claim 1, wherein theinstructions cause the processor to enable selection of a welding jointvia the mobile device.
 14. The weld training system of claim 1, whereinthe orientation device is a three dimensional material.
 15. The weldtraining system of claim 1, wherein the orientation device comprisesmagnets.
 16. The weld training system of claim 1, wherein theinstructions cause the processor to determine one or more of a traveldistance, a weld width, a depth, or an angle based on the at least oneof the position information or the orientation information.
 17. Anon-transitory machine readable storage medium comprising machinereadable instructions which, when executed by a processor of a mobiledevice, cause the processor to: in response to initiation of a weldoperation while the mobile device is mounted to a welding accessory,recognize identifiers on an orientation device based on images capturedvia a camera of the mobile device; determine at least one of positioninformation or orientation information for a welding torch with respectto the orientation device based on the recognized identifiers; anddisplay, via a display of the mobile device, the welding operation basedon the at least the position information or the orientation information.18. The non-transitory machine readable storage medium of claim 17,wherein the instructions cause the processor to display the weldingoperation within an augmented reality environment based on theidentifiers.
 19. The non-transitory machine readable storage medium ofclaim 18, wherein the instructions cause the processor to display asimulated weld joint and a simulated work surface based on therecognized identifiers.
 20. The non-transitory machine readable storagemedium of claim 18, wherein the instructions cause the processor todisplay the augmented reality environment including a live video ofactual objects used in the welding operation with one or more virtualobjects superimposed on the actual objects.